I finally received the build kit which included a copper clad card and a bottle of etchant. The parts were not exactly the same as the ones Ben and Felix used so it is unlikely the stl files would fit. The USB hub was quite large so I likely won't use it. I ordered some USB hub chips to be designed onto my PCB, but they won't arrive in time to be in this build. I removed the high components from the Raspberry Pi card, except the header, (I only removed the plastic from it). It will be soldered into my PCB and get trimmed flush with the PCB. There were 3 speakers in the kit, one was like the speakers in Ben's unit, the other 2 are larger and have wires attached. Not a big issue, but I don't think they would fit the original case. The battery is much smaller area wise - not sure about the depth. It is about the same area as the Raspberry Pi card. This may allow part of the device to be thinner - still deciding on that.
I created library parts for all the modules and components including the Raspberry Pi - so I could design a PCB to connect everything. This turned out to be a lot more work than creating normal library parts because there are no datasheets that have all the necessary dimensions for most of this stuff. I need all the connected through holes on each module to precisely line up with my PCB - very tedious measurements, offset calculations and reconciliation with what data is in the data sheets.
Once that library process was complete, designing and drawing the schematic was pretty quick, except I still have no info on what pins connect to the switch matrix rows and columns. If anyone can read Ben' schematic, I would love to see a jpeg of it.
Laying out the PCB was also pretty straight forward, but I'm hoping to nail down the rows and columns before printing....
Here is a quick look at some of the components after I modified them:
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